Method for carrying out a size change over in a packaging machine

ABSTRACT

A method for carrying out and verifying substitution and/or adjustments of mechanical components in an automatic packaging machine ( 1 ) during the size change over, said machine ( 1 ) being equipped with a computerized unit (UCC,  2 , D) for verifying and storing instructions related to the operations necessary to change over the size of the articles being processed. The operations include substitution of specific mechanical components and/or adjustment of the spatial positioning of specific mechanical components. Information elements relevant to the size change over are stored in the unit (UCC,  2 D) and are recalled and transferred to a palm-size computer ( 3 , E).

TECHNICAL FIELD

The present invention relates to the technical field concerningautomatic packaging machines for articles of different kinds.

In particular, the present invention relates to a method for carryingout and subsequently verifying substitutions and/or adjustments ofmechanical components of an automatic packaging machine during theso-called “size change over”, that is during the group of operationsperformed in order to allow the automatic packaging machine to work witharticles and/or packages of different size and/or shape.

BACKGROUND OF THE INVENTION

Generally, when the size is to be changed in an automatic packagingmachine, such as e.g. automatic machine for packaging articles intocard-board boxes or the like, to which the present description will makeexplicit reference without losing its universality, some mechanicalcomponents or parts thereof must be absolutely substituted with others,whose dimensions allow to work with new articles to be packaged and/orwith new boxes, while other components must be regulated/adjusted to thenew positions, in order to suit to the new dimensions or shapes of thenew articles and/or new boxes.

The above operations of substituting and/or adjusting of the mechanicalcomponents of the packaging machine are performed when the machine isoff-work, and are usually quite complex, which results in the need ofspecialized staff.

Moreover, the substituting and/or adjusting operations must be performedin a sequence, which is well-determined in relation to differentcomponents to be substituted/adjusted, and usually is defined accordingto precise procedures contained in the packaging machine operationmanual.

The operation manual also includes tables with identifying codes of newmechanical components which should replace the old ones, and whichshould be adjusted subsequently, so that they are easily found in themagazine.

The manual contains also tables with the values of new positions foreach component which is only to be adjusted.

Therefore, during the size change over, the operator must only makeconstant reference to the sequence defined in the manual, and first ofall, he/she must make constant reference to and remember the tables withthe new identifying codes and the new positioning values.

In order to facilitate the size change over operations, in the currentpackaging machines the information related to the working sequence andto the tables of values contained in the manual, is stored in centralcontrol units (PLC or PC of the machine) of the packaging machines andthus it can be visualized on outer displays connected to the centralunits and fastened to the machine carrying structures.

The size change over procedures currently used require a lot of time,not only due to the complexity of the substitution and adjustmentoperations, but mainly because the operator must constantly consult themanual of the packaging machine, or anyway he/she must constantly makereference to the information visualized on the display of the machinecentral control unit.

Moreover, the above procedure in practice is not reliable, becauseadjustment errors of a mechanical component may occur if the operatorforgets the exact new positioning value, or a component can besubstituted with an incorrect one, if the operator erroneouslyinterprets and memorizes the component identifying code written in themanual or visualized on the central control unit display.

Such errors result in an immediate stopping of the packaging machine,and in some serious cases, like for example in case of substitution oferroneous mechanical component, they can cause considerable damages tothe machine.

SUMMARY OF THE INVENTION

The object of the present invention is to propose a method for carryingout and subsequently verifying the size change over operations in anautomatic packaging machine, which allows avoiding the above mentioneddrawbacks of the procedures used at present.

In particular, an object of the present invention is to propose amethod, which allows, during the size change, carrying out substitutionsand/or adjustment of new components of the automatic packaging machinein a simple and rapid way, thus reducing considerably the possibility ofthe technical operators' operation errors.

In accordance with the present invention, a method is proposed forcarrying out and subsequently verifying substitutions and/or adjustmentsof mechanical components of an automatic packaging machine during a sizechange over, wherein the machine is equipped with a computer controlunit for storing instruction related to the operations to be performedin order to carrying out the size change over, said operations includingthe substitution of defined mechanical components and/or adjustment ofthe spatial positioning of defined mechanical components; the methodbeing characterized in that it includes recalling said storedinformation elements, related to the size change over, on the saidcomputer control unit and transferring said information elements ontoportable processing and computerized adjustment means, said portablemeans being equipped with means for detecting identifying codesassociated to said mechanical components; displaying, on said portablemeans, of a list of mechanical components to be substituted and/or whosepositioning is to be adjusted, together with information elementsrelevant to the mechanical components.

According to the proposed method, for each component to be replaced, thecorrectness of the component is checked by reading its identifying codeby suitable means of the portable processing means and comparing thedetected code with the information stored in the same portableprocessing means, the substituting component is then identified byreading and comparing a relative identifying code by suitable means ofthe portable means, and finally the component is substituted.

According to the proposed method, each component to be substituted isprecisely defined by detecting, using reading means mounted on theportable processing means, the component identifying code and comparingit with the information stored in the portable processing means, thenthe information concerning values corresponding to a new positioning ofthe component is displayed on the portable processing means, and finallythe component is adjusted according to the new positioning values,checking constantly the exact correspondence of the new values with thevalues displayed on the portable processing means.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described in more detail with reference toparticular, non-limiting embodiments and with reference to theaccompanying drawings, in which:

FIG. 1 is a schematic plan view of an automatic packaging machine, withsome parts removed for sake of clarity and some others shown in anenlarged way, in which the proposed method is applied;

FIG. 2 is a flow chart, defining the operation steps of the methodproposed by the present invention.

BEST MODE OF CARRYING OUT THE INVENTION

With reference to FIG. 1, the reference numeral 1 indicates an automaticpackaging machine, more precisely, but without limiting, a packagingmachine 1 for packaging articles into relative boxes made from cardboardor the like (not shown).

The machine 1 has the areas indicated respectively with A, B1 and B2,containing the working elements or mechanical components, which duringthe size change over must be substituted with others, whose dimensionsallow to work with new articles to be packaged and/or new boxes, and thecomponents which must be only regulated/adjusted to new positions, inorder to suit to the new dimensions or shapes of the new articles and/orthe new boxes.

More precisely, in FIG. 1 the reference letter A indicates the area ofthe machine 1 with mechanical components, like for example in FIG. 1,folding means of known type, which are aimed at folding edges or closingwings of the boxes heads.

These components have only spatial positioning to be adjusted by actingon known adjusting means 9 including worm screws, such as threaded rodswhich engages within suitable holes made on the folding means, to adaptthem to the new dimension of the flaps or wings of the boxes havingdifferent size.

The reference letters B1 and B2 indicate respectively areas, in which itis necessary to substitute some mechanical components with others ofsuitable dimensions, such as in FIG. 1 a pick-up component equipped withsuction cups aimed at removing, one by one, boxes in a blankconfiguration, from the bottom of a pile and at erecting the boxes (areaB1) and, respectively, a pusher element, aimed at introducing articlesinto each box (area B2).

In particular, the means 9 for adjusting the positioning of thecomponents situated in the area A, are connected to means 7 for checkingthe adjustment, such as in FIG. 1, numerical displays 7 of mechanicaltype, and are activated by the operator by means of a portable actuator5 of known type, such as a re-chargeable battery powered screw driver.

Each component has a known type bar code 6 a, whose function will beexplained better in the following, situated near the means 9 for thecomponent adjusting.

All the information elements necessary for the size change over, usuallycontained in the machine 1 operation manuals, such as informationelements concerning the working sequence and the tables with adjustingvalues of different components associated to different sizes, with whichthe machine 1 works, are stored in the memory of a central control unitUCC (namely a PLC o PC equipped with serial port or Input/Output device)of the packaging machine 1, and can be selected via a keyboard 2equipped with a mouse (not shown) and shown on a display or monitor D,connected to the unit UCC of the machine 1.

The method for carrying out substitution and/or adjustment of mechanicalcomponents, and for subsequently verifying them, according to thepresent invention and performed according to steps defined in the flowchart of FIG. 2, includes a first step, in which the operator recalls,on the computerized control unit UCC, the information and instructionsconcerning the substitution and/or adjustment of components related to aspecified size of articles and/or boxes.

When the operator has confirmed the selection of the desired size, allthe necessary information elements and working instruction aretransferred to portable recording and processing means 3, through aserial connection “RS232” of known type between the unit UCC and therecording means 3, obtained by e.g. a serial cable 4.

Preferably, the recording and processing means 3 include a knownpalm-size computer 3, equipped with autonomous power supply, its ownmemory units, a microprocessor and keyboard input means, and a screen Efor displaying the processed and stored data.

The palm-size computer 3 is connected to identifying codes reading means8, for example a bar-code scanner of known type.

It is to be understood that also other data acquiring means can be used,without leaving the protective scope of the present invention.

When the information and instructions coming from the unit UCC have beenstored in the memory of the palm-size computer 3, the palm-size computeris disconnected from the serial cable and the operator activates thedata processing on the basis of a program, installed previously on thepalm-size computer memories.

At this point, the operator can choose the option to follow theoperation step sequence suggested automatically on the screen E of thepalm-size computer 3 (FIXED OPTION), or the option to perform adjustingby beginning from any step chosen by the operator (RANDOM OPTION).

If the operator chooses the latter option, that is if the operatorchooses to work according to the flow section situated on the left ofthe flow chart of FIG. 2, operation can proceed by acting an a firstcomponent, e.g. situated in the area A of the packaging machine 1.

The operator reads the bar-code 6 a of the component to be adjusted bylaying the bar-code scanner 8 of the palm-size computer 3.

The palm-size computer 3 compares the scanned bar-code with theinstruction previously downloaded from the UCC and defines the valuescorresponding to an exact regulation of the component in relation to thechosen size.

Then, the operator acts, by the actuator 5, on the relative means 9, toadjust the component correct spatial positioning (height) until thedisplay 7 shows the same value as the one indicated on the screen E:thus, the operator can read visually the exact correspondence betweenthe two values as the confirmation of the perfect adjustment.

If a mechanical component does not have to be adjusted, the screen Eshows the writing “NO CHANGE” and the indication of the current value.

The above working sequence is repeated likewise for each chosencomponent.

Otherwise, if the operator wants to follow an operation step sequencesuggested automatically by the palm-size computer 3, that is accordingto the right part of the flow chart of FIG. 2, after having chosen thisoption, the operator finds the first component to be adjusted accordingto the instructions shown on the screen E.

After placing in position the bar-code scanner, the operator checks theexact correspondence of the component concerned with the indicatedvalues.

After the regulation/adjustment has been performed in a way as describedwith reference to the component selected in accordance to thepredetermined choice, the operator confirms the completion of theadjustment on the palm-size computer 3, so that the screen E of thecomputer shows the next component to be adjusted according to thesequence stored in the palm-size computer 3 memory.

The sequence of operations is repeated automatically for all componentsto be adjusted stored in the computer 3, until the whole adjustmentoperation is completed.

When the whole adjustment operation is completed, the screen E shows alist of all components, which have been adjusted in relation to thechosen size, so that the operator can advantageously check thecorrectness of the work performed, thus eliminating the possibility oferrors caused by potential omissions.

When all the components situated in the area B have been adjusted, thescreen E of the palm-size computer 3 visualizes a list of components tobe substituted in the areas B1 and B2 of the machine 1.

The list includes the exact identifying code, indicated with 6 b in FIG.1, of each new component which should substitute the one usedpreviously.

Then, at this point, the operator goes to the magazine to pick up thenew mechanical components, and identifies exactly, by means of thebar-code scanner 8, each component to be picked up by reading itsidentifying code 6 b, which is checked by the computer 3.

Afterwards, the operator returns to the machine 1 and substitutes theold components with the new ones, taken from the magazine, without anypossibility of error.

Similarly to the above described adjustment of the components in thearea A, when the whole substitution operation has been completed, thescreen E visualizes a list of all the components substituted in relationto the chosen size, so that the operator can advantageously and rapidlycheck the correctness of the work performed, thus eliminating thepossibility of errors caused by potential omissions.

As it is pointed out in the final part of the flow chart of FIG. 2, ifany operation has been omitted, the operator is informed by e.g. a soundalarm, and the cycle is resumed to be definitely completed.

All the adjustments and substitutions are constantly recorded andupdated in the memory of the UCC unit, so as to prepare the processingfor a possible future size change.

Obviously, the order of the previously described procedure steps can bechanged, i.e. it is possible to substitute the components first and toadjust the position of the components which do not have to besubstituted afterwards.

The instructions and information are generally transferred from the UCCto the palm-size computer 3 in only one block by only one downloadoperation.

In some cases, more download operations are possible, when the blocks ofinformation are particularly large or when the memory of the palm-sizecomputer 3 is limited.

Consequently, the use of portable recording and processing means,constituted by the palm-size computer 3 together with the bar-codescanner 8 and the bar-codes 6 a, 6 b prepared in the areas, where thesubstitution and/or adjustment operations are to be performed, makes itpossible for the operator to perform these operations safely, withoutany risk of error, and extremely rapidly (up to 70% of time saved withrespect to the normal size change over operations in a packagingmachine).

Moreover, the possibility to guide the operator's actions and toestablish an interaction between the operator and the recording andprocessing means, allows a path of the size change over operations to betraced through the most important steps, issuing, for each step and inany place and situation, information elements necessary for its bestcompletion.

Following one by one the indications supplied by the palm-size computer3 and applying the constantly updated measures visualized thereby, theoperator can perform even more size change operations in one working daywithout the need of constant access to the UCC, without reporting in anotebook or memorizing a series of codes or measured values, and withoutre-calculating values which must appear on the numerical displays 7, asit occurs at present.

1. A method for carrying out and subsequently verifying substitutionsand/or adjustments of mechanical components in an automatic packagingmachine during a change over to package products of a different sizecomprising: providing a computerized unit for verifying and storinginstructions related to each operation necessary for changing theautomatic packaging machine for processing articles of different size,said operations including substitution of specific mechanical componentsand/or adjustment of spatial positions of specific mechanical componentsof said machine; providing portable processing and recording meanshaving code reading means for reading identifying codes associated withsaid specific mechanical components; recalling information elementsrelevant to the size change over stored in said computerized unit andtransferring said information elements for display on said portablemeans, said information elements being a list of mechanical componentsto substitute and/or components whose positioning is to be adjustedtogether with information elements relevant to the mechanicalcomponents; reading the list, and locating the specific mechanicalcomponents to substitute and/or components whose positioning is to beadjusted, and, a) for each mechanical component to be substituted: i)using said code reading means of said portable processing means fordetecting said component identifying code on a mechanical component,comparing the detected code with the information elements stored in theprocessing means, and verifying the correctness of the mechanicalcomponent designated for substitution; ii) using said code reading meansof said portable processing means for detecting a substitute componentidentifying code on a mechanical component and comparing the substituteidentifying code for verifying the identity of the substitute component;and, iii) substituting the verified substitute component on the machine;b) and for each component whose position is to be adjusted: i) locatingthe component to be adjusted, using said code reading means of saidportable processing means for detecting said component identifying code,comparing the detected code with the information elements stored in theprocessing means, to verify that the correct component has been located;ii) displaying on said portable processing means information elementsrelevant to a new positioning of the component to be adjusted; and iii)carrying out the adjustment of said component while verifying the exactcorrespondence of said adjustment with said information elementsdisplayed on said portable processing means.
 2. The method according toclaim 1 wherein said component identifying codes are bar-codes situatedon the components; and providing an optical scanner with said portableprocessing and storing means for reading the bar-codes.
 3. The methodaccording to claim 2 wherein said portable processing and storing meansinclude a palm-size computer, and transferring the information elementsfrom said computerized unit to said palm-size computer.
 4. The method,according to claim 2 wherein said mechanical component is adjusted bydisplacing said mechanical component to said new position usingadjusting means coupled to the mechanical component, said adjustingmeans being associated with means for displaying corresponding numericalvalues relative to said new position.
 5. The method according to claim 1wherein said portable processing and storing means includes a palm-sizecomputer, and transferring the information elements from saidcomputerized unit to said palm-size computer.
 6. The method, accordingto claim 5 wherein said mechanical component is adjusted by displacingsaid mechanical component to said new position using adjusting meanscoupled to the mechanical component, said adjusting means beingassociated with means for displaying corresponding numerical valuesrelative to said new position.
 7. The method according to claim 1wherein said mechanical component is adjusted by displacing saidmechanical component to said new position using adjusting means coupledto the mechanical component, said adjusting means being associated withmeans for displaying corresponding numerical values relative to said newposition.